Abstract: A method of making a nickel iron (NiFe) layer and a cobalt or cobalt based layer of a free layer structure forms the cobalt or cobalt based layer by oblique ion beam sputter deposition with the cobalt or cobalt based layer located between the nickel iron (NiFe) layer and a copper (Cu) spacer layer of a spin valve sensor for reducing hard axis coercivity HCH which increases sensitivity and magnetic stability of a magnetic read head. An alpha iron oxide (&agr;FeO) layer on a nickel oxide (NiO) layer of a pinning layer may also be obliquely ion beam sputtered for improving magnetic stability of the read head.

Abstract: A CPP sensor includes a free layer which is located between first and second spacer layers and the first and second spacer layers are located between first and second AP pinned layer structures. Each of the AP pinned layer structures has first and second AP pinned layers with the first AP pinned layer of the first AP pinned layer structure interfacing the first spacer layer and the first AP pinned layer of the second AP pinned layer structure interfacing the second spacer layer. The second AP pinned layer of each of the first and second AP pinned layer structures is composed of a material which causes each AP pinned layer structure to be self-pinned. This eliminates the need for first and second antiferromagnetic (AFM) pinning layers so that the gaps of a read head employing the sensor and the resistance of the sensor are reduced to increase the linear read bit density of the read head and the magnetoresistive coefficient of the sensor respectively.

Abstract: An automated production process for the screening of the read-width (RW) and/or the stripe-height (SH) for every magnetoresistive (MR) read sensor element in a wafer substrate. The method of this invention uses the RW and/or SH values found with optical examination by electron microscopy of several of the MR sensor elements to estimate two substrate coefficients that relates the optical RW and SH measurements to heating-delta measurements, &dgr;=(RH−RC)/RC, where RH is the sensor resistance when hot and RC is the sensor resistance when cold, both of which can be measured using automated equipment. These relationships are sufficiently similar among all MR sensor elements manufactured on a single wafer substrate during a single manufacturing procedure that, when the hot resistance RH is measured at a constant applied voltage, the heating-delta, may be used with a first substrate coefficient to estimate the read-width RW of each MR sensor element for quality-control purposes during manufacture.

Abstract: A magnetic head assembly with an air bearing surface (ABS) layer over a double-shielded magnetoresistive (MR) sensor and a write gap formed between two spaced magnetic pole tips, with an optional write-gap shield disposed so that one magnetic pole tip is disposed between the write-gap shield and the other magnetic pole tip. At least one of the MR element shields is electrically connected to one of the MR signal lead conductors (preferably the one having the most positive potential) and the one magnetic pole tip (and/or the optional write-gap shield) is coupled to the clamped MR element shield with an electrical conductor. For multi-track read/write arrays, the connection between adjacent reader shield and writer pole and/or shield is provided independently for each read/write pair in the array, thereby equalizing the voltage environments to reduce variations in the chemical/mechanical erosion of the read and write head ABS layers.

Abstract: Various embodiments of a read head employ a bias stack which is in a sensor stack of the read head. The bias stack includes a biasing layer and is separated from a free layer in the sensor by a spacer layer. A magnetic moment of the free layer is longitudinally biased antiparallel to a magnetic moment of the biasing layer because of the coupling therebetween. The free layer is therefore more uniformly longitudinally biased than when hard bias layers are employed at first and second side surfaces of the sensor. Various methods are described for making the various read heads of the present invention.

Abstract: A perpendicular recording head has a second pole piece which includes a bottom ferromagnetic shaping layer and a top ferromagnetic probe layer. Each of these layers has a flare point where the layers first commence to widen after the ABS with the flare point of the shaping layer being located between an air bearing surface (ABS) of the head and the flare point of the probe layer. Further, the probe layer has a probe at the ABS which has a decreasing width from its top to its bottom to provide a trapezoidal shape which minimizes side writing due to skew of the probe at outermost and innermost circular tracks of a rotating magnetic disk.

Abstract: Longitudinal biasing of a free layer in a current perpendicular to the planes of the layers (CPP) type of sensor in a read head is implemented by pinning magnetic moments of first and second side portions of the free layer beyond the track width of the read head with first and second insulating antiferromagnetic (AFM) layers which are exchange coupled thereto. The pinning of the magnetic moments of the first and second side portions of the free layer pin and longitudinally bias the central active portion of the free layer within the track width so that the central portion of the free layer is magnetically stable.

Abstract: A spin valve sensor with a continuous junction is provided which has a sensor portion of a free layer longitudinally biased by first and second AFM biasing layers that are exchange coupled to first and second side portions of the free layer and a sensor portion of an AFM pinning layer that pins a sensor portion of a pinned layer perpendicular to the ABS in either a top spin valve or a bottom spin valve sensor.

Abstract: A spin valve sensor includes a spacer layer which is located between a free layer and an antiparallel (AP) pinned layer structure wherein the AP pinned layer structure includes an antiparallel coupling layer which is located between and interfaces first and second AP pinned layers with the second AP pinned layer interfacing the spacer layer. Each of the first and second AP pinned layers is composed of cobalt iron (CoFe) wherein the iron (Fe) content in the cobalt iron (CoFe) of one of the first and second AP pinned layers is greater than the iron (Fe) content in the cobalt iron (CoFe) in the other one of the first and second AP pinned layers.

Abstract: A single-sided, notched write head is provided for writing narrow erase band servo tracks as well as a double-notched write head, and for writing data tracks better than a double-notched write head. The single-sided, notched write head writes a narrow erase band on the notched side and a wide erase band on the unnotched side. In one embodiment, only one side of the first pole piece layer is notched, and in another embodiment a first side of the first pole piece layer is notched more than a second side. By writing servo tracks only a fraction of the track width of the write head, a wide erase band region is overwritten so that a narrow erase band is on each side of the servo track. Data tracks are written with a narrow erase band on one side and a wide erase band on the other side. The wide erase band on one side of the data track allows more flexibility in spacing the read head from adjacent tracks.

Abstract: A spin valve sensor includes an antiparallel (AP) pinned layer structure which is self-pinned without the assistance of an antiferromagnetic (AFM) pinning layer. A free layer of the spin valve sensor has first and second wing portions which extend laterally beyond a track width of the spin valve sensor and are exchange coupled to first and second AFM pinning layers. Magnetic moments of the wing portions of the free layer are pinned parallel to the ABS and parallel to major planes of the layers of the sensor for magnetically stabilizing the central portion of the free layer which is located within the track width. The spin valve sensor has a central portion that extends between the first and second AFM layers. First and second lead layers overlay the first and second AFM layers and further overlay first and second portions of the central portion so that a distance between the first and second lead layers defines a track width that is less than a distance between the first and second AFM layers.

Abstract: A spin valve sensor has an antiparallel (AP) pinned layer structure which has ferromagnetic first and second AP pinned layers that are separated by an antiparallel coupling layer. The first and second AP pinned layers are self-pinned antiparallel with respect to one another without the assistance of an antiferromagnetic (AFM) pinning layer. The spin valve sensor further includes an in-stack longitudinal biasing layer structure which is magnetostatically coupled to the free layer for longitudinally biasing a magnetic moment of the free layer parallel to an air bearing surface and parallel to major planes of the layers of the sensor. The only AFM pinning layer employed is in the biasing layer structure so that when the magnetic spins of the AFM pinning layer are set the orientations of the magnetic moments of the AP pinned layer structure are not disturbed.

Abstract: A cap layer structure is provided with a first layer composed of a metal and a second cap layer composed of a metal oxide. The first cap layer reflects conduction electrons back into the mean free path of conduction electrons and the second cap layer protects the first cap layer from subsequent processing steps without degrading the performance of the first cap layer.

Abstract: A pinning layer structure is provided for a spin valve sensor of a read head which has a reactively deposited nickel oxide first film which underlies a reactively sputter deposited second film of iron oxide (Fe2O3) or (Fe3O4). In the preferred embodiment the pinning layer is composed of cobalt (Co) or cobalt iron (CoFe) which is exchange coupled to the iron oxide (Fe2O3) or (Fe3O4) second film of the pinning layer. This structure results in an improved magnetoresistive coefficient (dr/R) which is substantially maintained after annealing so that the magnetic head has good thermal stability when subjected to high temperatures in the presence of a field that is antiparallel to the pinned orientation of the magnetic moment of the pinned layer.

Abstract: A magnetic head assembly has an open yoke type write head constructed on top of a read head so that the write head can be constructed with a very narrow track width without restraint by the requirements of the read head. The write head has first and second pole piece portions wherein the second pole piece portion has separate front and back layer portions. A coil layer is wrapped around only the first pole piece portion and the back layer portion so that the front layer portion can be constructed separately to provide a narrow track width. Further, in a preferred embodiment the front layer portion has a reduced thickness and a higher magnetic moment than the thickness and magnetic moment of the first pole piece portion and the back layer portion. Still further, in a preferred embodiment the first pole piece portion and the back layer portion are planar due to polarization of underlying layers.

Abstract: A pinned layer structure of a spin valve sensor is formed by sputter deposition of cobalt iron (CoFe) in a nitrogen (N2) atmosphere. This method permits a wider range of deposition times of a copper spacer layer to achieve a desirable ferromagnetic coupling field (HF) between the pinned layer structure and a free layer structure in the spin valve sensor.

Abstract: A dual spin valve sensor has a ferromagnetic free layer which is located between nonmagnetic first and second spacer layers wherein the first and second spacer layers are located between ferromagnetic first and second AP pinned layer structures and wherein the first and second AP pinned layer structures are located between and are exchange coupled to antiferromagnetic first and second pinning layers. In one aspect of the invention the free layer is composed of cobalt iron nickel (CoFeNi) for raising the resistance of the sensor and in another aspect of the invention first and second AP pinned layers in each of the first and second AP pinned layer structures are composed of cobalt iron (Co50Fe50) for further raising the resistance of the sensor to the sense current. The increase in the resistance of the sensor to the sense current increases the output signal of the sensor.

Abstract: A read head includes electrically conductive ferromagnetic first and second yoke layers and a tunnel valve sensor which is recessed from the ABS and is located between the first and second yoke layers. The first and second yoke layers extend to an air bearing surface (ABS) for conducting flux to the sensor and extend into the head beyond the sensor. A bottom copper structure interfaces a bottom surface of the tunnel valve sensor and a top copper structure interfaces a top surface of the tunnel valve sensor. In a first embodiment of the invention, the first and second copper structures conduct heat from the sensor to the first and second yoke layers respectively, and in a second embodiment of the invention the bottom copper structure conducts heat to a substrate while the top copper structure conducts from the sensor to the second yoke layer.

Abstract: A method of making a magnetic write head includes forming a strip of negative photoresist on a wafer at an ABS site with a width that defines a track width of the write head and which has a height above a desired height of a second pole tip. An alumina layer is formed on the wafer and on the strip with a thickness above the wafer that is equal to or greater than a desired height of the second pole tip. The alumina layer is then mechanically polished until the negative photoresist strip is exposed. The negative photoresist strip is then removed leaving an opening in the alumina layer after which the second pole tip is formed in the opening. In a first embodiment of the invention the second pole tip and the second pole piece yoke are one piece and are planar and in a second embodiment of the invention a P2 yoke is stitched to the second pole tip. In both embodiments the first pole piece of the write head can be notched without damaging the second pole tip.

Abstract: A horizontal combined head is provided which has both a thin film write and an MR read element located at an air bearing surface (ABS). The read element can be formed with a track width that is independent of the track width of the write element. The MR sensor or the read element is separated from one of the first and second pole pieces of the write element by an insulation layer. Accordingly, the shields for the read element remain more stable after a write operation. In one embodiment of the present invention a single stripe MR sensor is employed while in a second embodiment a dual stripe MR sensor is employed. A method of the invention includes forming the dual MR stripe in a single process step so that the dual MR stripes of the dual MR sensor are near identical for implementing near absolute common mode rejection of noise.